Building material



Aug. 30, 1932. J. H. DELANEY 1,374,922 I BUILDING MATERIAL I I FiledJuly 10, 1929 2 Sheets-Sheet 1 w g/4 w INVENTOR.

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1 -30,1932 J. H. DEWEY 1,814 9 2 BUILDING MATERIAL Filed July 10, 1929 2Sheets-Sheet 2 J/ "46 J' WWW/MW IN VEN TOR Y'TORNEY Patented Aug. 30,1932 7' [UNITED STATES JOHN H. DEWEY, 01 LOS ANGELES, CALIFORNIA, UNIONBANK 8b TRUST CO, OF I408 ANGELES, ADMINISTRATOR F SAID JQHN H.DELANEYQDEGEASED BUILDING MATERIAL Application filed July 10,

This invention relatesto building material, and especially to foldableboards that can be utilized to form cellular compartments, or hollowblocks, for walls, ceilings,

floors or the like.

. object, I provide a novel process whereby creases can be 'formed inplaster board to enable columnar or cellular shapes or blocks tobe'formed. Thus a knock down block is formed, easy to ship, inexpensiveto manufacture, and highly practical in use.

It is. another object of my invention to provide a convenient buildingunit that canv be. readily attached to the beams .or studdings thatsupport the walls or ceilings or floors;

2 and especially by the aid of overlapping or extending edges of theunitsfwhereby wall or fldor or ceiling structures can be constructed inavariety of ways, depending upon the manner in which the. units areassembled.

7 My invention possesses many other advantages, and has other objectswhich may be made more easily apparent frolnja consideration of a fewembodiments of my invention. For this purpose I have shown several forms$0 inthe drawings accompanying and forming part of the presentspecification. I shall now proceed to describe these forms in detail,which illustrate the general princlples of my invention; but it is to beunderstood that 1 .this detailed description is not to'be taken 1 in. alimiting sense, since the scope of my invention is best defined bythej'appended -c1aims. a

Referring to the drawings:

Figure 1 is a diagrammaticplan view of a machine arranged to form thenovel plaster Fig. 2 is a side elevation thereof v F 3 and 4 areperspective'views of two forms of laster board made in accordance withmy invention; Fi 5 is an end view showing how plaster boar constructedin accordance with Fig. 3

can be formed into a hollow block;

5 Fig. 6 is a view similar to'Fig. 1'5, but show-,

1929, Serial 110. 877,207.

ing how the plaster board of Fig. 4 can used to form a hollow block orconduit- Fig. 7 is a sectional view of a wall, ceillng, or floorstructure utilizing my invention Fig. 8 shows a modified form of myinvention, utilized in connection with a floor structure;

Fig. 9 is a perspective view-f a ioldable l plaster board that is amodification of the form shown in Fig. 3;

Fig. 10 is a plan view of the board shown 1 in Fig. 9, in foldedposition ,1

Fig. 11 'ndicates'how o'e' variety ofthe I .board can be used to form awall or partition 'insuch a way as completely to encompass or Imodification of the foldable board.

. Theapparatus for making the plaster board can in general be similar tothat disclosed in my prior application, Serial No.

278,537, entitled Wall covering and method of making same, and filed onMay 17,1928.

The machine is shown, therefore, merely diagrammatlcally. It can be madeso that the board is manufactured first in a continuous length, cutlater'oninto standard widths and lengths; or else the board can bemanufactured in predetermined sizes. In the form shown in Figs. 1 and 2,the process of manufacturing is shown as carried, on to form-acontinuous length of plaster board, the plastlc-filling beingaccommodated between a air of paper or cardboard-backin 11 an 12,

taken from supply rolls not s own. These backings form relativelyflexible supports for the filler material.

The bottom backing 11 is shown as fed over a guide roll 13 and a table14. :Above the table is ositioned'a hopper 15 into which the plasticlermaterial can be placed for deositing it onto the backing 11. Thisplastic ling, as disclosed in my prior application,

can be an effervescent gypsum mixture, to form cells and voids in thefinishing filling;

- or else there can be added a large percentage;

of zonolite, pumice, or other porous materi or mixtures thereof.Optionally, such poros- The material 16 delivered from opper onto themoving backin'g'material 11 is spread to form a substantially uniformand a relatively thick layer by the aid of the stationary shown, spacedapart uniformly. This is the bars 17 placed transversely above table 14.

The upper backing material 12'is fed over a roller. 18 and onto thematerial 17. One or more rolls 19 serve to form the three-layer materialto definite thickness.

As thus far described, the. apparatus is in no wise materially differentfrom that disclosed in my prior application. Before continuing with thedescription of the apparatus,

. attention is invited to the form of the product creases, such as 2 24,25, are provided, so-

that the plaster board can be folded on the creases to form a hollowconduit or block,

or to facilitate placing the board to form angles at the creases.Thesecreases as indicated in Fig. 3, can be made'in both the top andbottom, so that the backings 21, 22, nearly touch at or near a pointintermediate between the two main surfaces of theboard- In Fig. 4, aform of board is shown' that has but one backing 26. The filling 27 is,however, creased as indicated at 28, 29, 30, to permit folding at theselines. Filling 20, 27 can be solid or porous, as hereinbefore mentioned.The single backing form of Fig. 4can be made by leaving oil the topbacking material 12 while the machine of Figs. 1 and 2 operates.

In the form of the machine disclosed, the creases are formedlongitudinally of the backing materials by the aid of driven creasingrolls 31, 32 disposed either on top, or both on top and bottom of theplaster board as'it leaves the rolls 19, and while the filling thereinis still plastic. Greases 33, 34, 35 can thus be formed. The creasershoulders '36 on rollers 31, 32 can be arranged thereon in such a way asto secure the desired spacing and number of the creases; and it isintended that there'be supplied a number of sets of creaser rollerswith, different spacings and arrangement of the creasing shouldersthereon,

After the board passes the creasing rollers 31, 32, it may be preferableto subject it to another set of smoothing or pressure rolls 36.

Thence the material can be cut and dried in any well understood manner.I

The uses of the .creased material are many and varied. For example,hollow conduits resisting material. Any form of column can be thuscovered, by using appropriately proportioned creased boards.

As an example of the mode in which the creased board can be utilized toform insulating partitions, attention is called to Fig. 7. In thisinstance, wood studdings 40 are usual form of wall supports for houses.Between the studdings are'pla'ced the rectangular hollow blocks 41, ofthe general. form shown in Fig. 5. The short side 42 can first be nailedto the inner face of a studding, in such a way that its top edge isflush with the end surface ofthe studding. Thenthe opposite side 43'canbe correspondingly nailed onto the contiguous studding face, and thelong, upper side 44 can be folded over to complete the block, theextending edge'45 covering the edge of the studding, andnailed thereon.The space between the studdings can thus be completely covered.

Since the top sides 44. of 3.11 the blocks thus formed provide asubstantially continuous surface, and since the material from which thehollow block is made is non-inflammable,

the efiect is that a partition of substantially fire proof'character isprovided. Ordinarily,

a single layer of such hollow blocks is sufl'i-v sulating or sounddeadening material, such as hair felt, pumice, or the like The blockscan be used not only for wall partitions, but for many other purposes,such as ceilings and floors. In Fig. 8, I show a :floor structureutilizing my new materiaL' Upon a supporting'member 47 are fastened asby nailing, series of hollow blocks 48, filled if desired withfireproofing or heat insulating or sound deadening material. The blocksin this instanceare shown as trapezoidal in form, and as havingextending edges- 49,.

whereby grooves such as 50 can be formed between the blocks.' Into thesegrooves and above the blocks can be placed material 51" such as concreteor the like. to form the floor surface. The trapezoidal form of theblocks 48 provides a rigid supporting structure for material 51.

It is sometimes unnecessary that all four sides of the hollow block beof the same thick-- ness;- as for example, in Fig. 7, the external facesof the block only, need to be strong so as to support the finish layers,such as smooth plaster or stucco. In the form of block illustrated inFigs. 9 and 10, only the top side 52 is heavy, the other sides 53, 54,55 thin.

. This effect can obviously be secured by the aid of rollers acting onthe material in the course of manufacture, and while the plasticmaterial is still pliant.

In Fig. 11 I show a scheme whereby the i studding fora partition can beentirely encompassed by the blocks. In this instance, in stead of woodstuddings, I show evenly spaced structural iron columns 56. Around eachcolumn a block 57 is placed, the block being long enough to fillall theintervening distance from column to column. The columns are thus locatednext to a short side of the block, which can be filled in with heatinsulating or fire proof or sound absorbing material 58. To hold theblocks to the columns, clips 59, struck up from the columns, can beused. Furthermore, to prevent slipping between the blocks where theyabut, av projection 60 can be provided on one side of each block,fitting into a corresponding roove in the contiguous face of theadjacent lock. Thus a keying effect is provided.

It is of course understood that as many courses of the blocks shown inFigs. 7, 8 and 11- are used as necessary to complete the desiredpartition, wall, ceiling or floor. Thus in effeet I provide a knock downbuilding block that is easy to ship,1ight in weight, and inexpensive tomanufacture. It furthermore has highly desirable fireproofing and soundabsorption qualities.

'In Fig-.12, the hollow blocks 61 are shown as supported similarly tothose of Fig. 7 but there are added the metal rest bars 62 to providestrength, as for a flooring.

In Fig. 13, I show a creased board 63 in which the creases 64 in eachbacking 65 extend substantially as deeply as the thickness of the board,the sides 0 the opposite creases be 40 ing in contact. In this way, thebending of the board 63 in either direction is facilitated, the bendbeing accomplished at either of the I two creases.

I claim:

1. Building material havin a relatively thin flexible backing, and aller layer attached to the backing, said filler layer having parallelcreases across it, said creases being substantially V-shaped, the apexof the creases being close to the backing, and the filler materialbetweensome of the creases being thinner than between other creases. 1

2. Building material having a pairof relatlvely thin flexible backin anda filler layer between the backings am f attached thereto, said materialhaving a plurality of parallel creases across it, said creases beingsubstantially V-shaped the apex of the creases bein close to the backingopposite the creases, and

the' filler material between some of the creases being thinner thanbetween other creases.

In testimony whereof, I have hereunto set my hand.

" V JOHN H. DELANEY.

